Compact palletizer including a skeleton and a subassembly

ABSTRACT

A compact palletizer including a skeleton and a subassembly. Components of the skeleton are constructed of aluminum, which provides advantages over the prior art in terms of strength, rigidity, weight, and cost. The aluminum may be pretensioned or prestressed to provide these advantages. The subassembly is preferably mounted to the side of the skeleton. The compact palletizer is readily portable, and robotic elements of the compact palletizer do not need to be reprogrammed after transport, so installation time is substantially reduced compared with prior art palletizers.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a compact palletizer and the componentsthereof. The palletizer includes a skeleton and a subassembly. Thepresent invention utilizes materials and configurations which providefor advantages over the prior art in terms of cost, size, weight,portability, speed, and control.

2. Description of the Prior Art

Generally, palletizers are known in the prior art. Examples of relevantprior art documents include the following:

U.S. Pat. No. 6,718,229 for “Linear actuator palletizing system andmethod” by Takebayashi, filed Nov. 3, 2000, describes a method forprogramming a multi-axis actuator system to perform palletizing uses anintuitive user interface having a data entry screen for palletizingdata, which requires only a simple setting of minimal parametersincluding the number of rows and columns in a pallet and the pitchspacing between pallet positions. Actuator positions necessary forpalletizing movements are calculated in real time by an algorithmexecuted in a digital signal processor of the actuator controllers.Palletizing data entries are stored in a motion profile table in a rangeof consecutively paired indexes which is separated from the index rangededicated to regular single-step or torque moves.

U.S. Pat. No. 4,597,707 for “Automatic operating palletizer” byCornacchia, filed Aug. 17, 1984, describes an automatically operatingpalletizer which includes a vertical support column, a horizontallypositioned support beam, and means for movably mounting the horizontalsupport beam on the support column for vertical movement relative to thesupport column. A horizontally extending product beam is movably mountedon the horizontal support beam and extends perpendicularly thereto. Aproduct carrier is slidably mounted on the product support beam formovement along its length. Drive means are provided to drive thehorizontal support beam and the product support beam to a plurality ofvertical and horizontal positions relative to the support column, andalso to drive the product carrier along the support beam. As a resultthe product carrier is positioned at any of a plurality of predeterminedpositions in a three dimensional volume to move products from oneposition, e.g. a pickup station, to any of a plurality of otherpredetermined positions. The support column and various beams of thepalletizer are formed of light weight stainless steel.

U.S. Pat. No. 8,539,739 for “Method of palletizing items” by Pierson,filed Jul. 16, 2012, describes compact palletizers that include astretch-wrap operation as the pallet is built. A four-sided compactionmechanism compresses the rough-built load to the final pallet size andthen the entire layer is released to the pallet. Individual items orgroup of items are picked and placed onto a layer support device in aloose orientation. The loose orientation enables a much fasterpalletizing operation because the robotic arm that pick-and-places theitem, the items, or the row of items, can travel much faster as it doesnot have to precisely locate the item, items, or row of items. Duringthe time that a layer is being loosely constructed on the layer supportdevice concurrent wrapping can occur.

U.S. Patent Application Publication No. 2012/0213625 for “RoboticPalletizer Cell And Method Of Construction” by Roberts, filed Feb. 20,2012, describes a method of constructing a palletizer cell by providingsquare platform bases which are assembled into an array in abutment witheach other, each platform base mounting a respective component ofpalletizing equipment, such as a robot, one or more conveyors, a slipsheet bin, a discharge module, etc. with one platform base anchored tothe factory floor and the rest attached to one or another of theplatform bases to form the array of platform bases thereby properlylocating the various equipment with each other by the fitting togetherof the platform bases. Safety fencing sections are mounted atop one ormore outer sides to substantially enclose the space within thepalletizer cell. Each platform base is formed with side openings whichmay be engaged with the tines of a fork lift.

U.S. Pat. No. 8,371,797 for “Secured palletization facility” byBonhomme, filed Sep. 25, 2008, describes a facility including a robot(2) for supplying pallet preparation stations with products (3) of thecrate type or different. The structure of the facility includes sidewalls (11) and doors (13, 14) for accessing the palletization stations Aand B. The structure further includes a fixed wall (15) separatingstations A and B, and a cowling (20) mobile from one station to theother and in the shape of a dihedron, for alternatively converting eachpalletization station A and B into a kind of pallet hatch, wherein saidconversion is carried out automatically before the opening of the doorfor accessing a loaded pallet located in said hatch. The cowling (20) isdirectly actuated by the product handling robot (2).

U.S. Pat. No. 4,082,194 for “Self-contained pallet-elevating bagpalletizer” by Sheehan, filed Jun. 30, 1976, describes a wheel-supportedpalletizer frame structure that has an empty-pallet magazine containingan empty pallet stack from the bottom of which empty pallets aredelivered one by one to a hydraulic scissors pallet elevator while therearward ends of the pallets remaining in the stack are temporarilylifted. The pallet elevator has a table which is raised and then loweredstep-by-step by a hydraulic scissors mechanism from successive elevatedpositions wherein the platform or each tier of bags thereon is loweredin timed relationship with a rotary and reciprocable open-ended bagpositioner. Filled bags are fed one-by-one to either of the oppositeends of the bag positioner from a horizontal bag conveyor aligned withthe bottom of the bag positioner and coupled thereto for travel back andforth therewith. The bag positioner is rotatable between either of twolongitudinal positions aligned with the conveyor and movable into anyone of a plurality of lateral positions disposed transverse to said bagconveyor. The bag positioner is also movable laterally of the bagconveyor to position the bags dropped therefrom onto differentlongitudinal positions parallel to the bag conveyor. The bag positioneris also mounted for motion transverse to the direction of motion of thebag conveyor to deposit the bags in different lateral positionsperpendicular to the bag conveyor. The open-ended bag positioner enablesindividual bags to be swung horizontally to positions 90° and 270° apartin order to position the sewed end of each bag on the inside of eachtier of the stack of bags on the pallet. The four-wheeled mount of theentire machine enables it to be moved bodily to any desired positionupon the floor of the warehouse or other palletizing building.

U.S. Pat. No. 7,993,095 for “Mobile split palletizer” by Reichler, filedOct. 30, 2010, describes a modular split palletizer for loading layersof articles on stackable pallets. The palletizer has a frame supportingfirst, second, and third sections. The first section includes a layerbuild area and a first portion of a stacker transfer track. The secondsection includes a tier sheet bin, a top frame bin, and a second portionof the track. The third section includes a pallet build area and a thirdportion of the track. Each of the first, second, and third sections canbe disassembled, moved individually and independently, and re-assembledat a new location to form the complete palletizer. Also disclosed is amethod of relocating the modular split palletizer. With the palletizerat one location, the utilities connected to the palletizer aredisconnected, the fasteners holding the sections together are released,and the sections are separated. The disassembled sections are moved tothe new location and reassembled.

None of the prior art references discloses the compact palletizer of thepresent invention, specifically a compact palletizer with features suchas a cantilevered x-axis, a pre-tensioned double x-axis structure, a4-rail x-axis system, modular x, z, y, and theta subassemblies, modulardesign, wheels for mobility, forklift access, unibody frame constructionwherein the x-axis structure is also part of the skeleton, integratedsafety panels, compact height, a non-welded frame, an assembly that isnot top mounted, and an extruded aluminum profile frame.

SUMMARY OF THE INVENTION

The present invention relates to a compact palletizer and the componentsthereof. The palletizer includes a skeleton and a subassembly. Thepresent invention utilizes materials and configurations which providefor advantages over the prior art in terms of cost, size, weight,portability, speed, and control. Specifically, an extruded aluminumprofile frame as utilized in a compact palletizer of the presentinvention is advantageous over the construction of palletizers of theprior art. The present invention also provides for a pre-tensioned,4-rail x-axis system as well as a compact palletizer which can be movedwithout requiring reassembly for operation.

One embodiment of the present invention is a compact palletizerincluding a skeleton including a base, a frame, and an x-axis structureand an assembly including an x-axis subassembly, a z-axis subassembly,and a y-axis subassembly, wherein the frame includes a multiplicity ofvertical posts and a multiplicity of horizontal bars, wherein the x-axisstructure includes two horizontal support beams rigidly fixed betweentwo vertical end plates, wherein the x-axis subassembly is affixed tothe x-axis structure, and the x-axis subassembly provides an interfacefor mounting at least two z-axis mounts of the z-axis subassembly to thex-axis subassembly, wherein the at least two z-axis mounts provide forhorizontal movement of the z-axis subassembly, wherein the z-axissubassembly includes a chassis subassembly and a spine having a top endand a bottom end, wherein the chassis subassembly is operable to movevertically along the spine and wherein the y-axis subassembly isattached to the z-axis subassembly via the chassis, wherein the y-axissubassembly includes an arm including an end of arm tooling (EOAT)subassembly for moving at least one object, wherein neither the y-axissubassembly, the z-axis subassembly, nor the x-axis subassembly aremounted from the top of the compact palletizer or from the multiplicityof horizontal bars, and wherein the frame, the x-axis structure, and theassembly do not include welded components.

Another embodiment of the present invention is a compact palletizerincluding a skeleton including a steel base, a frame, and an x-axisstructure, and an assembly including an x-axis subassembly, a z-axissubassembly, a y-axis subassembly, and a theta-axis subassembly, whereinthe frame includes a multiplicity of vertical extruded aluminum profileposts, wherein the x-axis structure includes two horizontal extrudedaluminum profile support beams rigidly fixed between two verticalaluminum end plates, and two aluminum v-guide rail mounts parallel tothe two horizontal support beams, wherein the x-axis subassemblyincludes the four v-guide rails, wherein the four v-guide rails areaffixed to the two aluminum v-guide rail mounts such that the fourv-guide rails provide an interface for mounting at least two z-axismounts to the x-axis subassembly via at least two aluminum z-axismounts, wherein the at least two aluminum z-axis mounts provide forhorizontal movement of the z-axis subassembly via the four v-guiderails, wherein the z-axis subassembly includes a spine having a top endand a bottom end, wherein the spine includes two structural extrudedaluminum profile components, wherein the bottom end includes anattachment point for an idle sprocket, wherein the top end includes anattachment point for mounting a motor, a gear reducer, and a drivesprocket, wherein the z-axis subassembly further includes a chassissubassembly including a multiplicity of bearing blocks attached to achassis, wherein the chassis subassembly is operable to move verticallyalong the spine, wherein the y-axis subassembly is attached to thez-axis subassembly via the chassis, wherein the y-axis subassemblyincludes an arm comprised of two spaced apart structural extrudedaluminum profile arm components, wherein the two spaced apart structuralextruded aluminum profile arm components are spaced apart to allow forinsertion of a timing belt, wherein two linear rails are mounted to thetop of the two spaced apart structural extruded aluminum profile armcomponents so that they are parallel to the two spaced apart structuralextruded aluminum profile arm components, wherein the y-axis subassemblyfurther includes four bearing blocks for mounting the theta-axissubassembly, and wherein the theta-axis subassembly includes an end ofarm tooling (EOAT) subassembly for moving at least one object, a motor,and a precision rotary bearing subassembly.

Yet another embodiment of the present invention is a compact palletizerincluding a skeleton including a steel base and a frame, and anassembly, wherein the frame includes a multiplicity of vertical extrudedaluminum profile posts and a multiplicity of horizontal extrudedaluminum profile bars and wherein the assembly includes an arm with anend of arm tooling (EOAT) subassembly for moving at least one object.

Another embodiment of the present invention is a compact palletizerincluding a skeleton including a steel base and a frame, and an assemblyincluding an arm with an end of arm tooling (EOAT) subassembly formoving at least one object, wherein the compact palletizer does notmeasure more than about 3.35 meters in height when assembled, andwherein a stack height of the compact palletizer is at least about 2.57meters.

These and other aspects of the present invention will become apparent tothose skilled in the art after a reading of the following description ofthe preferred embodiment when considered with the drawings, as theysupport the claimed invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective front view of a palletizer with nopanels according to the present invention.

FIG. 2 illustrates a front view of a palletizer according to the presentinvention.

FIG. 3 illustrates a perspective rear view of a palletizer with nopanels according to the present invention.

FIG. 4 illustrates a side view of a palletizer according to the presentinvention.

FIG. 5 illustrates a top view of a palletizer according to the presentinvention.

FIG. 6 illustrates a perspective front view of a palletizer with panelsaccording to the present invention.

FIG. 7 illustrates a perspective rear view of a palletizer with panelsaccording to the present invention.

FIG. 8 illustrates an end view of a square profile of extruded aluminumprofile used in one embodiment of the present invention.

FIG. 9 illustrates an end view of a rectangular profile of extrudedaluminum profile used in one embodiment the present invention.

FIG. 10 illustrates a perspective view of a skeleton of a compactpalletizer, showing an x-axis structure with a partial frame andillustrating the divergence of the vertical posts of the frame from thevertical during assembly according to the present invention.

FIG. 11 illustrates a perspective view of part of the skeleton 200having an x-axis structure, a steel base, and a partial frame accordingto the present invention.

FIG. 12 illustrates a perspective back view of a palletizer skeletonaccording to the present invention.

FIG. 13 illustrates a front view of a palletizer skeleton according tothe present invention.

FIG. 14 illustrates a perspective front view of a palletizer skeletonaccording to the present invention.

FIG. 15 illustrates a side view of a palletizer skeleton presentinvention.

FIG. 16 illustrates a top view of a palletizer skeleton according to thepresent invention.

FIG. 17 illustrates a perspective view of the x-axis subassemblyaccording to the present invention.

FIG. 18 illustrates an exploded view of the x-axis subassembly accordingto the present invention.

FIG. 19 illustrates a front view of an assembly illustrating the x-axissubassembly and the z-axis subassembly according to the presentinvention.

FIG. 20 illustrates a back view of an assembly illustrating the x-axissubassembly and the z-axis subassembly according to the presentinvention.

FIG. 21 illustrates the y-axis assembly according to the presentinvention.

FIG. 22 illustrates a perspective view of an assembly illustrating thex-axis subassembly, the z-axis subassembly, the y-axis subassembly, andthe theta-axis subassembly according to the present invention.

FIG. 23 illustrates a perspective exploded view of an assemblyillustrating the x-axis subassembly, the z-axis subassembly, the y-axissubassembly, and the theta-axis subassembly according to the presentinvention.

FIG. 24 illustrates a side view of an assembly illustrating the x-axissubassembly, the z-axis subassembly, the y-axis subassembly, and thetheta-axis subassembly according to the present invention.

FIG. 25 illustrates a perspective front view of a palletizer with apallet feed according to the present invention.

FIG. 26 illustrates a perspective front view of a palletizer withstretch wrapping and box buffering accessories according to the presentinvention.

FIG. 27 illustrates a perspective front view of a depalletizer withoutpanels according to the present invention.

FIG. 28 illustrates a front view of a depalletizer without panelsaccording to the present invention.

FIG. 29 illustrates a side view of a depalletizer without panelsaccording to the present invention.

FIG. 30 illustrates a top view of a depalletizer according to thepresent invention.

FIG. 31 illustrates a perspective front view of a depalletizer withpanels according to the present invention.

DETAILED DESCRIPTION

Referring now to the drawings in general, the illustrations are for thepurpose of describing a preferred embodiment of the invention and arenot intended to limit the invention thereto.

The present invention provides a compact palletizer including a skeletonand a subassembly. In one embodiment, the skeleton includes a base, aframe, and an x-axis structure. Preferably, the base is constructed ofsteel. Preferably, the frame and/or the x-axis structure is constructedof extruded aluminum profile. In another embodiment, some of thecomponents of the base, frame, and/or the x-axis structure areconstructed of aluminum. Preferably, vertical posts of the frame and thex-axis structure are constructed of extruded aluminum profile. In oneembodiment, the compact palletizer does not include any panels.

In one embodiment, the x-axis structure includes two horizontal supportbeams (top horizontal support and bottom horizontal support) rigidlyfixed between two vertical end plates, and two plates parallel to thetwo horizontal support beams serving as v-guide rail mounts. Preferably,the two vertical end plates are two precision cut aluminum plates. Thetwo vertical end plates set the spacing between the two horizontalsupport beams and to insure parallel assembly of these components.Preferably, the two horizontal support beams are constructed out ofextruded aluminum profile. The two vertical end plates are preferablyperpendicularly affixed to the two horizontal support beams. Preferably,the two horizontal support beams are rigidly fixed between two verticalend plates using bolts and are not welded. Preferably, the x-axisstructure does not flex. Preferably, the two plates parallel to the twohorizontal support beams serving as v-guide rail mounts are rigidlyaffixed to the two vertical end plates using bolts and are not welded.

FIG. 1 illustrates a perspective front view of a palletizer with nopanels according to the present invention, showing the compactpalletizer 100 having motors 110, a conveyer 140, vertical posts of theframe 210, horizontal bars of the frame 215, corner braces 220, a steelbase 250, forklift pockets 260, wheels 270, v-rails 350, plates formounting v-rails 355, timing belts 360, a spine 420, and an end of armtooling (EOAT) assembly 440.

FIG. 2 illustrates a front view of a palletizer according to the presentinvention, showing the compact palletizer 100 having a conveyer 140,vertical posts of the frame 210, horizontal bars of the frame 215,corner braces 220, a steel base 250, forklift pockets 260, wheels 270, aspine 420, and an end of arm tooling (EOAT) assembly 440.

FIG. 3 illustrates a perspective rear view of a palletizer with nopanels according to the present invention, showing the compactpalletizer 100 having motors 110, z-axis mounting extruded aluminumprofile components, a conveyer 140, vertical posts of the frame 210,horizontal bars of the frame 215, corner braces 220, a steel base 250,forklift pockets 260, wheels 270, a top horizontal support beam 310, abottom horizontal support beam 320, a spine 420, and an end of armtooling (EOAT) assembly 440.

FIG. 4 illustrates a side view of a palletizer according to the presentinvention, showing the compact palletizer 100 having a motor 110,v-roller mount and belt tensioner 120, a conveyer 140, vertical posts ofthe frame 210, horizontal bars of the frame 215, corner braces 220, asteel base 250, forklift pockets 260, wheels 270, v-rails 350, platesfor mounting v-rails 355, timing belts 360, and a spine 420.

FIG. 5 illustrates a top view of a palletizer according to the presentinvention, showing the compact palletizer 100 having a conveyer 140,forklift pockets 260, and wheels 270.

In another embodiment, the present invention includes a skeleton havinga base, a frame, and an x-axis structure and panels. Preferably, theframe is constructed of extruded aluminum profile. Preferably, thepanels are constructed of polycarbonate. The polycarbonate panels addstrength, rigidity, and stiffness to the structure, as well as creatinga safe enclosure. In another embodiment, the panels include aluminumdiamond plate. The panels provide security and safety by partiallyenclosing the compact palletizer. In one embodiment, the panels becomean integral part of the assembly, thus adding even more rigidity to thealready rigid palletizer.

In one embodiment, the compact palletizer also includes glass panelsand/or glass doors. The glass panels and/or glass doors are operable tomake the interior of the palletizer accessible, as well as to providevisibility into the interior of the palletizer.

FIG. 6 illustrates a perspective front view of a palletizer with panelsaccording to the present invention, showing the compact palletizer 100having motors 110, a conveyer 140, vertical posts of the frame 210,horizontal bars of the frame 215, corner braces 220, a steel base 250,forklift pockets 260, wheels 270, and a spine 420.

FIG. 7 illustrates a perspective rear view of a palletizer with panelsaccording to the present invention, showing the compact palletizer 100having motors 110, a conveyer 140, vertical posts of the frame 210,horizontal bars of the frame 215, corner braces 220, panels 230,forklift pockets 260, wheels 270, and a spine 420.

Although extruded aluminum profile is preferred for use in the skeleton,other material that is lightweight, has a high tensile strength, and hasa high impact resistance can be utilized in the compact palletizer ofthe present invention. However, stainless steel is preferred forembodiments in the food and food preparation industry because ofsanitation concerns. In particular, aluminum is known to collect dust,bacteria, and other contaminants. Therefore, steel tubing may be usedinstead of extruded aluminum profile where avoidance of collection ofdust, bacteria, and other contaminants is desired or required. Becausemore processing and machining is required for steel, steel wouldpreferably only be used in specific applications where aluminum wouldnot be a suitable material.

Aluminum, and more specifically extruded aluminum profile, is preferredfor use in the frame and subassembly components of the present inventionbecause it provides lightweight material with high rigidity, tensilestrength and impact resistance. Importantly, traditional engineeringprinciples teach away from the use of extruded aluminum profile materialfor a compact palletizer machine because it would increase vibration inthe overall structure, which would be disadvantageous. However,surprisingly, the compact palletizer of the present invention in itspreferred embodiment using extruded aluminum profile is constructed andconfigured under pretensioning and prestressing with bolted connectionsthat minimize or eliminate vibration. Thus, the present invention solvesa longstanding, unmet need for a lightweight, strong, and compactpalletizer using extruded aluminum profile that is constructed andconfigured as described herein to overcome prior art disadvantages withimproved structure and faster installation.

In alternative embodiments, specific applications may provide for use ofother suitable lightweight, strong metals and metal alloys. Inparticular, suitable metals and metal alloys include magnesium,titanium, beryllium, and combinations thereof. More specifically,magnesium may be combined with silicon carbide to form a lightweightmetal with record strength. Additionally, a metal alloy comprised oflithium, magnesium, titanium, aluminum, and scandium may be used in theframe and/or subassembly components of the present invention. However,aluminum, and more specifically extruded aluminum profile, is preferredin the present invention because of availability, cost, its highstrength, and its light weight. Extruded aluminum profile is preferredfor use in the frame of the skeleton because it is a lightweightmaterial with high rigidity, tensile strength and impact resistance.Notably, the extruded aluminum profile frame of the present invention isbolted, not welded. Bolting allows more rapid assembly and easier repairthan welding. Additionally, assembly by bolting is currently more costeffective than welding. The compact palletizer is readily portable, androbotic elements of the compact palletizer do not need to bereprogrammed after transport, so installation time is substantiallyreduced compared with prior art palletizers.

The extruded aluminum profile frame designed and constructed accordingto the present invention provides unexpectedly improved properties overthe prior art. Rather than merely substituting one material (aluminum)for another (such as steel), and obtaining expected results, using analuminum palletizer provides for enhanced rigidity and stability over asteel palletizer. Using aluminum in components of the palletizer of thepresent invention also provides for use of smaller motors and gears whencompared to motors and gears of a steel palletizer, thereby reducing theweight of the compact palletizer even further.

Additionally, one of ordinary skill in the art would not be motivated touse extruded aluminum profile in the structural components of apalletizer because of concerns about vibrations, rigidity, anddurability of an aluminum palletizer.

FIG. 8 illustrates an end view of a square profile of extruded aluminumprofile used in one embodiment the present invention. The end view showsprecision cut, countersunk holes 375. Preferably, this extruded aluminumprofile is used in the horizontal bars of the frame of the presentinvention. However, any component constructed of extruded aluminum mayhave this end profile.

FIG. 9 illustrates an end view of a rectangular profile of extrudedaluminum profile used in one embodiment of the present invention. Theend view shows precision cut, countersunk holes 375. Preferably, thisextruded aluminum profile is used in the vertical posts and horizontalbeams of the frame of the present invention. However, any componentconstructed of extruded aluminum may have this end profile.

There has also been a long-felt but unmet need to provide a palletizerthat is easily and efficiently assembled. The compact palletizer of thepresent invention requires a group of people only 2-3 hours to assembleas opposed to prior art palletizers, which would take an identical orsimilar group of people 2-3 days to construct. A compact palletizer ofthe present invention is also movable, as it is on wheels. The compactpalletizer is also transportable, solving a long-felt but unmet need.Additionally, the robotic elements of the compact palletizer arepreprogrammed and merely require re-homing or re-zeroing, notreprogramming, upon assembly or transport, which solves a long-felt butunmet need of providing a palletizer that does not require reprogrammingafter being transported to function. There has also been a long-feltneed to make palletizers lighter due to concerns about cost andportability, yet an aluminum palletizer has not been successfullycommercialized. Another long-felt need is to make palletizers more costeffective, which the present invention provides in one embodiment byproviding a palletizer with a frame that can be assembled using bolts,which are more cost effective than welding.

Prior art palletizer frames are typically constructed of steel and heldtogether by welding. The prior art is disadvantageous in that weldingsteel together is not precise. Additionally, welding steel togetherprovides for a permanently bonded x-frame which is not adjustable. Incontrast, the present invention provides for an aluminum x-frame whichis precisely assembled and, if necessary or desired, could be adjustedby unfastening the bolts with appropriate tools, adjusting the frame,and refastening the bolts. A surprising advantage of using extrudedaluminum profile and bolts, and preferably a pretensioned extrudedaluminum profile frame, for construction of the x-frame is that thex-frame is sufficiently rigid, stable, and vibration-less to allow thepalletizer to be operated extensively and transported without losingcalibration.

Preferably, the palletizer includes a base. In one embodiment, the baseis comprised of steel tubing and steel plates. Preferably, the steeltubing and steel plates are welded together to form the base of thecompact palletizer. Accommodation is made in the base for positioning apallet and/or for adding accessories such as conveyors for automaticinfeed of empty pallets and outfeed of loaded pallets. The frame alsosets the vertical angle (preferably between 1 degree and 2 degreesoutward) of the x-frame support columns for tensioning the frame. Palletinfeed is unique for a palletizer of this size. Pallet build-up withpallet feed is also unique. The base preferably includes access for theforks of a forklift to lift and reposition the entire compactpalletizer. Preferably, the access for the forks of the forklift arecomprised of steel to make the access for the forklift strong anddurable and to prevent damage from the forklift. The access for theforks of the forklift are preferably pockets.

Additionally, the base preferably includes wheels for mobility. Thecompact palletizer is preferably moveable via the wheels, preferably viaphysical force resulting from one or more persons pushing and/or pullingthe compact palletizer.

The frame of the present invention preferably includes at least onex-frame, at least one y-frame, and at least one z-frame. An x-framepreferably includes a top horizontal support beam and a bottomhorizontal support beam. The x-frame is preferably constructed ofextruded aluminum profile connected with bolts. Preferably, the x-frameis pretensioned or prestressed. The x-frame is attached to the base andframe by attaching the base beam and the bottom horizontal support beamto vertical posts of the frame. The base beam and bottom horizontalsupport beam are preferably designed and configured such that thevertical posts are angled about 1-2 degree outward at the top. When thetop horizontal support beam is attached to the vertical posts, thedivergence of the columns is eliminated. This provides for apretensioned or prestressed x-frame when assembled. Thus, when the tophorizontal support beam is attached, preferably via bolts, the tops ofthe vertical end plates are brought inward towards the vertical, andpositioned to be substantially vertical or preferably completelyvertical, bringing the entire x-frame under tension. The precision ofthe x-assembly is provided for by the manufacture process of thevertical posts of the frame, the endplates, the top horizontal supportbeam, and the bottom horizontal support beam. The endplates areprecision cut, for example laser-cut. The endplates preferably alsoinclude countersunk holes for precision attachment to the horizontalx-axis support. The endplates are preferably attached to the verticalposts of the frame via bolts. The top horizontal support beam and thebottom horizontal support beam are preferably extruded with internalsolid rods, cylinders, or similar shapes which allow for the precisionplacement of tapped holes. The extrusion process makes the tappingprocess more precise than other methods. The internal solid rods,cylinders, or similar shapes are preferably tapped (threaded), and theend plates are preferably bolted to these tapped holes; the countersunkholes provide for the precision alignment of the end plates and thehorizontal x-axis supports.

When assembling the frame, the vertical posts are preferably slightlyangled outward at the top or bottom when attached to the top or bottomsupport and the lower x-frame support so that when the frame is pulledtogether at the third support, sufficient tension is created in theskeleton to provide stability. Thus, the skeleton is preferablypre-tensioned or pre-stressed to create rigidity in the structure.

FIG. 10 illustrates a perspective view of a skeleton of a compactpalletizer, showing an x-axis structure with a partial frame andillustrating the divergence of the vertical posts of the frame from thevertical during assembly according to the present invention, showingpart of the skeleton 200 showing vertical posts of the frame 210, thedivergence of the vertical posts of the frame from the vertical duringassembly by about 1 degree to about 2 degrees, a steel base 250,forklift pockets 260, wheels 270, v-rails 350, plates for mountingv-rails 355, and a vertical end plate 370.

FIG. 11 illustrates a perspective view of part of the skeleton 200having an x-axis structure, a steel base, and a partial frame, showingvertical posts of the frame 210, a steel base 250, forklift pockets 260,wheels 270, v-rails 350, plates for mounting v-rails 355, and a verticalend plate 370.

The frame of the present invention preferably includes corner braces.These corner braces provide increased stability and rigidity for theframe.

FIG. 12 illustrates a perspective back view of a palletizer skeletonaccording to the present invention, showing the palletizer skeletonhaving vertical posts of the frame 210, horizontal bars of the frame215, corner braces 220, a steel base 250, forklift pockets 260, wheels270, a top horizontal support beam 310, and a bottom horizontal supportbeam 320.

FIG. 13 illustrates a front view of a palletizer skeleton according tothe present invention, showing the palletizer skeleton having verticalposts of the frame 210, horizontal bars of the frame 215, corner braces220, a steel base 250, forklift pockets 260, and wheels 270.

FIG. 14 illustrates a perspective front view of a palletizer skeletonaccording to the present invention, showing the palletizer skeleton 200having vertical posts of the frame 210, horizontal bars of the frame215, corner braces 220, a steel base 250, forklift pockets 260, wheels270, v-rails 350, plates for mounting v-rails 355, and a vertical endplate 370.

FIG. 15 illustrates a side view of a palletizer skeleton presentinvention, showing the palletizer skeleton 200 having vertical posts ofthe frame 210, horizontal bars of the frame 215, corner braces 220, asteel base 250, forklift pockets 260, wheels 270, v-rails 350, andplates for mounting v-rails 355.

FIG. 16 illustrates a top view of a palletizer skeleton according to thepresent invention, showing wheels 270.

The present invention preferably includes an assembly, wherein theassembly includes an x-axis subassembly, a z-axis subassembly, a y-axissubassembly, and a theta-axis subassembly.

The present invention preferably includes an x-axis subassembly. In oneembodiment, the x-axis subassembly is side mounted to the x-axisstructure and includes 4 v-guide rails. Advantageously, the 4 v-guiderails are spaced apart to reduce friction in operation of the gantry.Preferably, the x-axis subassembly does not flex.

The x-axis subassembly can be described as a gantry, which istop-mounted in the prior art. However, the gantry of the presentinvention is preferably side-mounted. Mounting the gantry on the side asin the present invention reduces the overall height of the compactpalletizer, which results in a more readily portable compact palletizerfor a variety of stack heights when compared to those of the prior art.

Preferably, the gantry includes a parallel, 4 rail system. The 4 railsystem includes two pairs of opposing v-rails, wherein the verticalassembly moves on the first pair of the v-rails and the second pair ofv-rails prevents the vertical assembly from jumping off the first pairof v-rails. The x-axis is designed such that the first pair of v-railsare maintained parallel to each other and such that the second pair ofv-rails are maintained parallel to each other. In one the horizontalassemblies are centered via flat head screws using the holes in the endof the vertical assembly.

By having the gantry side-mounted on the frame, as opposed totop-mounted, the height of the palletizer is reduced, providing a morecompact palletizer than possible in the prior art for a variety ofpalletizers with different stacked pallet heights. The compactpalletizer is also more readily portable than the palletizers of theprior art.

In one embodiment, the x-axis subassembly includes at least one timingbelt to move the z-axis subassembly horizontally. In another embodiment,the x-axis subassembly includes two belts, preferably a top belt and abottom belt. This doubles the capacity and prevents binding, therebyallowing a larger load to be moved more quickly than for a single belt.

Using extruded aluminum profile for an x-axis subassembly has presentedissues in the prior art, particularly with respect to vibrations. Forthis reason, the most common material used in palletizer subassemblieshas been steel. However, there is a longstanding unmet need for apalletizer that is lighter than a steel palletizer and more readilyportable than a steel palletizer, but that maintains a rigidity andstability equivalent or even superior to a steel palletizer. Notably,even if the x-axis subassembly were to be fastened with bolts,vibrations are known to cause release of bolts. However, the presentinvention solves this problem by utilizing a pretensioned x-axissubassembly to prevent or substantially reduce vibrations and preventthe x-axis from shifting and to prevent release of bolts duringoperation or transport. These were unexpected results. As discussedabove, the use of extruded aluminum profile in an x-axis subassembly ora palletizer frame is not obvious to one of ordinary skill in the art.In fact, one of ordinary skill in the art would discourage the use ofbolted aluminum because vibrations and impact from the operation and/ortransport of the palletizer would present issues such as the vibrationsand impact loosening the bolts, rendering the palletizer less stable. Bysubstantially reducing and even eliminating vibrations in the operationof the palletizer, and by eliminating the loosening of bolts when thepalletizer is transported, the present invention provides unexpectedlyimproved properties over the prior art when extruded aluminum profile isused in the x-assembly and/or in the frame of the palletizer. Thesubassembly and/or frame is preferably pretensioned or prestressed up toabout 1150 Newtons (or up to about 258 lbs-force). However, thesubassembly and/or frame is preferably pretensioned or prestressedproportional to the dimensions of the frame. A compact palletizer tallerthan about 3.35 meters may be pretensioned or prestressed to more thanabout 1150 Newtons (or more than about 258 lbs-force). Alternatively,the x-axis can be pretensioned by angling the multiplicity of extrudedaluminum profile vertical posts between about 1 degree to about 2degrees from the vertical. The x-axis can also be pretensioned byangling the multiplicity of extruded aluminum profile vertical postsbetween about 0 degrees and about 2 degrees from the vertical. The topand bottom x-frame support beams are attached to the x-frame supportcolumns, preferably by bolting. The bolting, when combined with theangling of the x-frame support columns about 1-2 degrees from thevertical, provides a pretensioned x-assembly which substantially reducesor eliminates vibrations during operation of the palletizer.

FIG. 17 illustrates a perspective view of the x-axis subassembly 300according to the present invention, showing v-rails 350, plates formounting v-rails 355, vertical end plates 370, and precision cut,countersunk holes 375.

FIG. 18 illustrates an exploded view of the x-axis subassembly 300according to the present invention, showing a top horizontal supportbeam, v-rails 350, plates for mounting v-rails 355, and vertical endplates 370.

The subassembly includes a z-axis subassembly, a y-axis subassembly, anda theta-axis subassembly. The z-axis subassembly, the y-axissubassembly, and/or the theta-axis subassembly of the compact palletizeris preferably manufactured from lightweight profiled structuralmaterial, such as profiled aluminum. Preferably, the z-axis subassembly,the y-axis subassembly, and/or the theta-axis subassembly arepretensioned or prestressed.

The z-axis subassembly preferably utilizes two structural aluminumprofile components for mounting the spine to the x-axes. These arepreferably mounted to the pair of opposing v-rails with 8 v-wheelbearings which provide for x-axis motion. The spine includes two linear,opposing rails for the z-axis movement of the y-arm. Preferably, thez-axis movement of the y-arm is precision guided by two linear rails and4 bearing blocks. Holes and/or slots are also included, preferably atthe top end of the profile, to mount a motor, a gear reducer and a drivesprocket. Preferably, slots and/or holes are provided at the bottom ofthe profile to mount the idle sprocket. Attached to bearing blocks thatslide on the linear rails is a chassis that is designed to take up theslack and tension in the chain that raises and lowers the arm. Notably,the z-axis subassembly does not flex.

FIG. 19 illustrates a front view of an assembly 400 illustrating thex-axis subassembly and the z-axis subassembly according to the presentinvention, showing motors 110, v-roller mount and belt tensioner 120,v-rails 350, plates for mounting v-rails 355, a vertical end plate 370,and a spine 420.

FIG. 20 illustrates a back view of an assembly 400 illustrating thex-axis subassembly and the z-axis subassembly according to the presentinvention, showing motors 110, v-roller mount and belt tensioner 120, atop horizontal support beam 310, a bottom horizontal support beam 320,plates for mounting v-rails 355, a vertical end plate 370, and a spine420.

The y-axis subassembly preferably includes an arm which utilizes twopieces of structural aluminum profile spaced apart to allow forinsertion of a timing belt. The y-axis subassembly is preferablyattached to the z-axis subassembly via the chassis of the z-axissubassembly. The y-axis subassembly is preferably attached to the thetasubassembly between an idle pulley and a drive pulley. Mounted to thetop of the arm are two linear rails and 4 bearing blocks that guide they-axis subassembly and theta subassembly. In one embodiment, the end ofthe profile includes holes to set spacing. In another embodiment,t-slots are also included for attaching side gussets. The bottom of thearm preferably includes a cable track tray. The arm is preferably acantilever arm. The y-axis subassembly/arm can preferably flex betweenabout 0 millimeters (about 0 inches) and about 3.175 millimeters (about⅛ inch) under full load, which in one embodiment is about 100 kg (orabout 220 lbs). In another embodiment, the y-axis subassembly/arm canpreferably flex between about 0 millimeters (about 0 inches) and about1.5875 millimeters (about 1/16 inch) under partial load, which in oneembodiment is about 50 kg (or about 110 lbs). This amount of flex isslightly more than in a steel structure, but is not enough to causeperformance issues. In fact, the assembly is lighter a steel structureand can be moved faster and more precisely with smaller motors.

FIG. 21 illustrates the y-axis subassembly 422 according to the presentinvention, showing a motor 110, bearing blocks 425, linear rails 427,and a timing belt for y-axis motion 429.

The present invention preferably includes a theta axis subassembly forrotating an end of arm tooling (EOAT) assembly used to move items fromthe conveyor to be stacked on a pallet or vice versa. The theta axisassembly is preferably mounted to the 4 bearing blocks on the y-axissubassembly. The EOAT assembly preferably moves back and forth on they-axis arm via the theta axis subassembly. The theta axis subassemblypreferably carries a motor and precision rotary bearing assembly thatallows the load to be rotated up to about 365 degrees in eitherdirection.

The EOAT assembly acts as the interface between the palletizer and theitems loaded and/or unloaded by the palletizer, including box(es),bag(s), and/or pail(s). The EOAT assembly will have many variations tofit specific customer requirements. Basic units will handle single,double, triple or more boxes, as well as one bag (up to 36 kg [80 lbs])at a time or multiple pails (up to 3 at a time). The palletizer can useany EOAT appropriate for the palletizing task. By way of example and notlimitation, adjustable bag grippers, side clamps, fork-style tools,and/or vacuum technology tools can be utilized. However, any prehensileend effector can be used, including impactive, ingressive, astrictive,and contigutive end effectors. Impactive effectors include jaws or clawswhich physically grasp the object by using direct impact upon theobject. Ingressive effectors include pins, needles or hackles whichphysically penetrate the surface of the object (used in textile, carbonand glass fiber handling). Astrictive effectors are those that produce abinding force using a field, and include vacuum, magneto- orelectroadhesion. Contigutive effectors require direct contact foradhesion to take place, such as glue, surface tension, or freezing.

Notably, the x, y, z, and theta subassemblies are modular in order tofacilitate assembly and disassembly. In one embodiment, the frame of thepresent invention is integral. Notably, the compact palletizer of thepresent invention is readily portable, while being rigid, lightweight,and compact. The rigidity of the compact palletizer allows thepalletizer to remain precise and accurate in the placement of itemsafter transport, and even several transports. Precision is achieved bysmall tolerances. Rigidity prevents larger tolerances from developing.Transport does not affect the accuracy or precision of the compactpalletizer. The robotic elements of the compact palletizer arepreferably preprogrammed, and merely need to be re-homed or re-zeroedafter transport.

FIG. 22 illustrates a perspective view of an assembly illustrating thex-axis subassembly, the z-axis subassembly, the y-axis subassembly, andthe theta-axis subassembly according to the present invention, showingmotors 110, v-roller mount and belt tensioner 120, a chassis 130,v-rails 350, plates for mounting v-rails 355, vertical end plates 370, aspine 420, and a rotary bearing 430.

FIG. 23 illustrates a perspective exploded view of an assemblyillustrating the x-axis subassembly, the z-axis subassembly, the y-axissubassembly, and the theta-axis subassembly according to the presentinvention, showing motors 110, v-roller mount and belt tensioner 120, achassis 130, v-rails 350, plates for mounting v-rails 355, vertical endplates 370, a spine 420, and a rotary bearing 430.

FIG. 24 illustrates a side view of an assembly illustrating the x-axissubassembly, the z-axis subassembly, the y-axis subassembly, and thetheta-axis subassembly according to the present invention, showingmotors 110, a chassis 130, vertical end plates 370, a spine 420, and arotary bearing 430.

The compact palletizer can preferably be assembled rapidly. The portableconstruction of the compact palletizer allows easy assembly at a site,merely requiring attachment of the spine, the z-axis subassembly andset-up of the robotic elements. Preferably, the robotic elements of thecompact palletizer are preprogrammed and merely require re-homing orre-zeroing, not re-programming, upon assembly or transport. Notably, thecompact palletizer of the present invention requires a group of peopleonly 2-3 hours to assemble as opposed to prior art palletizers, whichwould take an identical or similar group of people 2-3 days to constructfrom single components.

In another embodiment, the compact palletizer has a unitary andintegrated uni-body construction.

The compact palletizer is notably lightweight when compared with thepalletizers of the prior art. A base frame comprising a welded steelframe with fork pockets and wheels, wherein the welded steel frameincludes steel tubing and steel plates welded together, wherein theframe also sets a vertical angle of about 1 degree to about 2 degreesoutwards of the posts for tensioning. The frame weighs approximately 290kg (638 lbs) in one embodiment of the present invention. Lightweight—themoving subassemblies, z-, y- and theta-axes, manufactured from extrudedaluminum profile materials weigh about 237 kg (631 lbs) in oneembodiment of the present invention. An x-axis structure v-guide railmount, comprised of 2 pieces of structural aluminum profile, twoprecision cut aluminum plates for mounting the 4v-guide rails, and 2precision cut aluminum plates to set the spacing between the top andbottom rails and to insure parallel assembly of the top and bottom railsweighs approximately 70 kg (154 lbs) in one embodiment of the presentinvention. A base frame, x-axis structure, and skeleton (structuralaluminum profile frame) which does not include any panels, but includesvertical posts which are slightly angled outwards (approximately betweenabout 1 degree and 2 degrees), wherein the skeleton is prestressed,weighs approximately 495 kg (or approximately 1089 lbs) in oneembodiment of the present invention. A z-axis subassembly which utilizestwo structural extruded aluminum profile components for the spine, whichare mounted to the two v-guide bearing assembles for x-axis motion andto two linear rails for vertical stroke of the arm, wherein the twostructural aluminum profile components include holes in the end of theprofiles, slots to mount a motor, gear reducer, and drive sprocket, andslots at the bottom to mount an idle sprocket, wherein the twostructural extruded aluminum profile components also include a chassisattached to the bearing blocks that slide on the linear rails, weighsapproximately 160 kg (or approximately 352 lbs) in one embodiment of thepresent invention. A y-axis subassembly which includes an arm utilizingtwo pieces of structural extruded aluminum profile, having two linearrails and 4 bearing blocks mounted to the top of the arm, with holes inthe end of the profile to set the spacing and to utilize t-slots forattaching side gussets, wherein the bottom of the arm includes a cabletrack tray, weighs approximately 55 kg (or approximately 121 lbs) in oneembodiment of the present invention. A theta axis subassembly, whichcarries a motor and a precision rotary bearing assembly, weighsapproximately 22 kg (or approximately 48.4 lbs) in one embodiment of thepresent invention. An end of arm tooling (EOAT) assembly weighs betweenapproximately 5 kg (or approximately 11 lbs) and approximately 50 kg (orapproximately 110 lbs) in one embodiment of the present invention. Thus,the total compact palletizer assembly weighs approximately 1451 kg (orapproximately 3192 lbs) in one embodiment of the present invention.

The lighter weight of the compact palletizer provided by using extrudedaluminum profile in the palletizer makes the gross weight lower, andthus allows for the use of smaller motors and gears, thereby reducingthe weight of the compact palletizer even further. This unexpectedresult of using smaller motors and gears, and further reducing theweight of the palletizer is advantageous over the prior art.Additionally, the pairs of the rails on the x-axis provide stability andrigidity for the palletizer and prevent binding, allowing the assemblyto move at much faster speeds than possible in the prior art. By way ofexample, a load of about 100 kg can be moved at about 1000 mm/sec (orabout 3.3 ft/sec). If the load is lighter, the load can be moved evenfaster, depending on the stability of the product and EOAT design, up toabout 2000 mm/sec (or about 6.5 ft/sec). The ability to move loadsfaster by using aluminum for key components of the palletizer, andtherefore lighter motors and gears, is yet another unexpected andnonobvious result. Additionally, velocity and acceleration of the loadscan be adjusted and/or optimized in the present invention.

The compact palletizer of the present invention optionally includesaccessories. Notably, accessories do not impact the envelope of thecompact palletizer. The accessories are preferably modular and attach tothe compact palletizer from the outside. One accessory is a palletin-feed. The pallet in-feed is operable to be positioned to enter thepalletizer from the left, right, front, and/or back; in other words, thepallet in-feed is operable to be positioned to enter the palletizer fromany side.

FIG. 25 illustrates a perspective front view of a palletizer 100 with apallet feed 500 according to the present invention, showing motors 110,a conveyer 140, horizontal bars of the frame 215, corner braces 220,panels 230, a steel base 250, wheels 270, and an end of arm tooling(EOAT) assembly 440.

Additionally, a conveyer of the pallet in-feed has multiple “zones” inone embodiment of the present invention. These zones provide forseparating the loads into discrete segments on the conveyer, preferablyvia sensing technology such as lasers, IR, etc., and optimize managementand processing of the loads into the palletizer. Yet another accessoryis a box buffering system. The box buffering system is preferablycombined with the conveyer to provide for an auto-feed pallet in-feedsystem. A tier sheet dispenser may also be utilized in one embodiment ofthe present invention. The tier sheet dispenser is preferably unique fora compact palletizer having a stack height of about 2.57 meters (orabout 8 feet 5 inches), with a total height of about 3.35 meters (orabout 11 feet), and for a compact palletizer having a stack height ofabout 1.52 meters (or about 5 feet), with a total height of about 2.43meters (or about 8 feet). Tier sheets are utilized between layers ofproduct stacked on a pallet and create a more stable/transportable unit.Due to the size of the tier sheet, numerous engineering concerns wereaddressed to add the tier sheet dispenser to a compact palletizer ofthis size, specifically a compact palletizer having a stack height ofabout 2.57 meters (or about 8 feet 5 inches), with a total height ofabout 3.35 meters (or about 11 feet), or a compact palletizer is acompact palletizer having a stack height of about 1.52 meters (or about5 feet), with a total height of about 2.43 meters (or about 8 feet). Dueto the size of the palletizer envelope, a tier sheet is dispensed one ata time into the palletizer through a side or rear panel. Anotheraccessory includes a stretch wrapper. In one embodiment, the stretchwrapper is integrated into the frame. Preferably, the stretch wrapperprovides for stretch wrapping an entire pallet complete with its load.In another embodiment, the stretch wrapper is operable to wrap loadsindividually. In yet another embodiment, the stretch wrapper is operableto stretch wrap more than one load together.

FIG. 26 illustrates a perspective front view of a palletizer 100 withstretch wrapping and box buffering accessories according to the presentinvention, showing vertical posts of the frame 210, panels 230, a boxbuffering system 600, a tier sheet dispenser 700, a stretch wrapper, and800, and a large capacity vacuum blower mounted in a silencer box 900.

The compact palletizer of the present invention preferably is operableto be constructed in many sizes. A preferred size of the compactpalletizer is a compact palletizer having a stack height of about 2.57meters (or about 8 feet 5 inches), with a total height of about 3.35meters (or about 11 feet). In another embodiment, a preferred size ofthe compact palletizer is a compact palletizer having a stack height ofabout 1.52 meters (or about 5 feet), with a total height of about 2.43meters (or about 8 feet). The present invention can place product ontostandard size USA or European pallets. Notably, the palletizer of thepresent invention has a stack height to palletizer height ratio of ashigh as about 0.767.

Another embodiment of the present invention provides for a depalletizer.The depalletizer of the present invention is similar to the compactpalletizer of the present invention, and utilizes many of the samecomponents. However, the depalletizer preferably uses a longer x-axis.In one embodiment, the x-axis of the depalletizer is about 10 feet.Preferably, the depalletizer can use any end-of-arm tool appropriate fordepalletizing. Any prehensile end effector can be used, includingimpactive, ingressive, astrictive, and contigutive. Impactive effectorsinclude jaws or claws which physically grasp by direct impact upon theobject. Ingressive effectors include pins, needles or hackles whichphysically penetrate the surface of the object (used in textile, carbonand glass fibre handling). Astrictive effectors are those that produce abinding force using a field, and include vacuum, magneto- orelectroadhesion. Contigutive effectors requiring direct contact foradhesion to take place (such as glue, surface tension or freezing). In apreferred embodiment, side clamps are used to unload a layer. In oneembodiment, the arm of the depalletizer can move up to approximately 100kg (or approximately 220 lbs). In one embodiment, the depalletizer has acamera that is operable to view and/or detect that a pallet is twisted,shifted, or skewed, as well as the nature and degree of the twisting,shifting, and/or skewing. Preferably, the camera is top-mounted abovethe arm. In one embodiment, the depalletizer can handle up to about 8inches of skew (i.e. a load being up to about 8 inches off of thepallet) before correction is needed. In one embodiment, the depalletizerincludes an assembly for correcting the twisting, shifting, and/orskewing.

In one embodiment, the depalletizer does not include panels.

FIG. 27 illustrates a perspective front view of a depalletizer 101without panels according to the present invention, showing a motor 110,vertical posts of the frame 210, horizontal bars of the frame 215,forklift pockets 260, wheels 270, v-rails 350, plates for mountingv-rails 355, timing belts 360, and a spine 420.

FIG. 28 illustrates a front view of a depalletizer 101 without panelsaccording to the present invention and shows a motor 110, vertical postsof the frame 210, horizontal bars of the frame 215, a steel base 250,forklift pockets 260, wheels 270, and an end of arm tooling (EOAT)assembly 440.

FIG. 29 illustrates a side view of a depalletizer 101 without panelsaccording to the present invention, showing a motor 110, v-roller mountand belt tensioner 120, vertical posts of the frame 210, horizontal barsof the frame 215, a steel base 250, forklift pockets 260, wheels 270,v-rails 350, plates for mounting v-rails 355, timing belts 360, and aspine 420.

FIG. 30 illustrates a top view of a depalletizer 101 according to thepresent invention, showing forklift pockets 260 and wheels 270.

In another embodiment, the depalletizer includes panels. Preferably, thepanels are constructed of aluminum and/or polycarbonate. The aluminumpanels add strength, rigidity, and stiffness to the structure, and thepolycarbonate panels add visibility as well as creating a safeenclosure. The panels provide security and safety by partially enclosingthe compact palletizer. In one embodiment, the panels become an integralpart of the assembly, thus adding even more rigidity to the alreadyrigid palletizer.

In one embodiment, the depalletizer also includes clear polycarbonatepanels and/or clear polycarbonate doors. The polycarbonate panels and/orpolycarbonate doors are operable to make the interior of the palletizeraccessible, as well as to provide visibility into the interior of thepalletizer.

FIG. 31 illustrates a perspective front view of a depalletizer 101 withpanels according to the present invention, showing a motor, verticalposts of the frame 210, horizontal bars of the frame 215, panels 230,forklift pockets 260, wheels 270, v-rails 350, plates for mountingv-rails 355, and a spine 420.

The above-mentioned examples are provided to serve the purpose ofclarifying the aspects of the invention and it will be apparent to oneskilled in the art that they do not serve to limit the scope of theinvention. All modifications and improvements have been deleted hereinfor the sake of conciseness and readability but are properly within thescope of the present invention.

The invention claimed is:
 1. A compact palletizer comprising: a skeletonincluding a base, a frame, and an x-axis structure; and an assemblyincluding an x-axis subassembly, a z-axis subassembly, and a y-axissubassembly, wherein the frame includes a multiplicity of vertical postsand a multiplicity of horizontal bars; wherein the x-axis structureincludes two horizontal support beams rigidly fixed between two verticalend plates; wherein the x-axis subassembly is affixed to the x-axisstructure, and the x-axis subassembly provides an interface for mountingat least two z-axis mounts of the z-axis subassembly to the x-axissubassembly, wherein the at least two z-axis mounts provide forhorizontal movement of the z-axis subassembly; wherein the z-axissubassembly includes a chassis subassembly and a spine having a top endand a bottom end, wherein the chassis subassembly is operable to movevertically along the spine and wherein the y-axis subassembly isattached to the z-axis subassembly via the chassis; wherein the y-axissubassembly includes an arm including an end of arm tooling (EOAT)subassembly for moving at least one object; wherein neither the y-axissubassembly, the z-axis subassembly, nor the x-axis subassembly aremounted from the top of the compact palletizer or from the multiplicityof horizontal bars; wherein the frame, the x-axis structure, and theassembly do not include welded components; and wherein the compactpalletizer further includes a plurality of panels comprised ofpolycarbonate and/or aluminum, wherein the plurality of panels areaffixed to the multiplicity of vertical posts and/or the multiplicity ofhorizontal bars.
 2. The compact palletizer of claim 1, wherein themultiplicity of vertical posts, the multiplicity of horizontal bars, thetwo horizontal support beams, and the two vertical end plates areconstructed of extruded aluminum profile, and wherein the spine includesextruded aluminum profile components.
 3. The compact palletizer of claim2, wherein the multiplicity of vertical posts, the multiplicity ofhorizontal bars, the two horizontal support beams, and the two verticalend plates are pretensioned or prestressed.
 4. The compact palletizer ofclaim 2, wherein during assembly of the compact palletizer, themultiplicity of vertical posts are affixed to the base between about 1degree and about 2 degrees from a plane vertically perpendicular to thebase, such that when the multiplicity of horizontal bars are affixed tothe multiplicity of vertical posts, the multiplicity of vertical postsbecome oriented vertically perpendicular to the base and themultiplicity of vertical posts and the multiplicity of horizontal barsare pretensioned or prestressed by the vertically perpendicularorientation of the vertical posts.
 5. The compact palletizer of claim 1,wherein the two horizontal support beams are rigidly fixed between thetwo vertical end plates via a first set of bolts and the multiplicity ofhorizontal bars are affixed to the multiplicity of vertical posts via asecond set of bolts.
 6. The compact palletizer of claim 1, wherein theassembly further comprises a theta-axis subassembly, wherein thetheta-axis subassembly is mounted on the y-axis subassembly and thetheta-axis subassembly includes an end of arm tooling (EOAT) subassemblyfor moving at least one object, a motor, and a precision rotary bearingsubassembly.
 7. The compact palletizer of claim 1, wherein the compactpalletizer has a stack height of about 1.52 meters, with a total heightof about 2.43 meters.
 8. A compact palletizer comprising: a skeletonincluding a steel base, a frame, and an x-axis structure; and anassembly including an x-axis subassembly, a z-axis subassembly, a y-axissubassembly, and a theta-axis subassembly: wherein the frame includes amultiplicity of vertical extruded aluminum profile posts; wherein thex-axis structure includes two horizontal extruded aluminum profilesupport beams rigidly fixed between two vertical aluminum end plates,and two aluminum plates for mounting rails, wherein the two aluminumplates are parallel to the two horizontal support beams; wherein thex-axis subassembly includes two sets of rails, wherein the two sets ofrails are affixed to the two aluminum plates: wherein the two sets ofrails are connected to roller mounts such that each set of the two setsof rails is connected to one roller mount, wherein the roller mountsprovide for horizontal movement of the z-axis subassembly via the twosets of rails and the roller mounts; wherein the z-axis subassemblyincludes a spine having a top end and a bottom end, wherein the spineincludes two structural aluminum components, wherein the bottom endincludes an attachment point for an idle sprocket, wherein the top endincludes an attachment point for mounting a motor, a gear reducer, and adrive sprocket, wherein the z-axis subassembly further includes achassis subassembly including a multiplicity of bearing blocks attachedto a chassis, wherein the chassis subassembly is operable to movevertically along the spine, wherein the y-axis subassembly is attachedto the z-axis subassembly via the chassis; wherein the y-axissubassembly includes an arm comprised of two spaced apart structuralextruded aluminum profile arm components, wherein the two spaced apartstructural extruded aluminum profile arm components are spaced apart toallow for insertion of a timing belt, wherein two linear rails aremounted to the top of the two spaced apart structural extruded aluminumprofile arm components so that they are parallel to the two spaced apartstructural extruded aluminum profile arm components, wherein the y-axissubassembly further includes four bearing blocks for mounting thetheta-axis subassembly; and wherein the theta-axis subassembly includesan end of arm tooling (EOAT) subassembly for moving at least one object,a motor, and a precision rotary bearing subassembly.
 9. The compactpalletizer of claim 8, wherein the frame, the x-axis structure, and theassembly do not include welded components.
 10. The compact palletizer ofclaim 8, wherein the multiplicity of vertical extruded aluminum profileposts and the two horizontal extruded aluminum profile support beams arepretensioned or prestressed.
 11. The compact palletizer of claim 8,wherein the frame further comprises a multiplicity of horizontalextruded aluminum profile bars affixed to the multiplicity of verticalextruded aluminum profile posts, and wherein during assembly of thecompact palletizer, the multiplicity of vertical extruded aluminumprofile posts are affixed to the steel base between about 1 degree andabout 2 degrees from a plane vertically perpendicular to the steel base,such that when the multiplicity of horizontal extruded aluminum profilebars are affixed to the multiplicity of vertical extruded aluminumprofile posts, the multiplicity of vertical extruded aluminum profileposts become oriented vertically perpendicular to the steel base and themultiplicity of vertical extruded aluminum profile posts and themultiplicity of horizontal extruded aluminum profile bars arepretensioned or prestressed by the vertically perpendicular orientationof the vertical extruded aluminum profile posts.
 12. The compactpalletizer of claim 11, wherein the two horizontal extruded aluminumprofile support beams are rigidly fixed between the two verticalaluminum end plates via a first set of bolts, wherein the two sets ofrails are affixed to the two aluminum plates via a second set of bolts,and the multiplicity of horizontal extruded aluminum profile bars areaffixed to the multiplicity of vertical extruded aluminum profile postsvia a third set of bolts.
 13. The compact palletizer of claim 11,further comprising a plurality of panels comprised of polycarbonateand/or aluminum, wherein the plurality of panels are affixed to themultiplicity of vertical extruded aluminum profile posts and/or themultiplicity of horizontal extruded aluminum profile bars.
 14. Thecompact palletizer of claim 8, wherein the end of the y-axis subassemblywhich is not attached to the chassis is operable to flex between about 0millimeters and about 3.175 millimeters from a plane horizontallyperpendicular to the x-axis subassembly.
 15. The compact palletizer ofclaim 8, further comprising a stretch wrapper operable to stretch wrap apallet and a load of the pallet.
 16. The compact palletizer of claim 8,wherein the compact palletizer further includes robotic elements,wherein the robotic elements are preprogrammed such that the compactpalletizer does not require reprogramming after transport or assembly.17. The compact palletizer of claim 8, wherein the compact palletizerhas a total height of about 2.57 meters and a stack height of about 2.44meters.
 18. A compact palletizer comprising: a skeleton including asteel base and a frame; and an assembly, wherein the frame includes amultiplicity of vertical posts and a multiplicity of horizontal bars;wherein the assembly includes an arm with an end of arm tooling (EOAT)subassembly for moving at least one object; and wherein during assemblyof the compact palletizer, the multiplicity of vertical posts areaffixed to the steel base between about 1 degree and about 2 degreesfrom a plane vertically perpendicular to the steel base, such that whenthe multiplicity of horizontal bars are affixed to the multiplicity ofvertical posts, the multiplicity of vertical posts become orientedvertically perpendicular to the steel base and the multiplicity ofvertical posts and the multiplicity of horizontal bars are pretensionedor prestressed by the vertically perpendicular orientation of thevertical posts.
 19. The compact palletizer of claim 18, wherein theskeleton further includes an x-axis structure and wherein the assemblyfurther includes an x-axis subassembly, a z-axis subassembly, and ay-axis subassembly; wherein the x-axis structure includes two horizontalextruded aluminum profile support beams rigidly fixed between twovertical aluminum end plates, and two aluminum plates for mountingrails, wherein the two aluminum plates for mounting rails are parallelto the two horizontal support beams; wherein the x-axis subassemblyincludes two sets of rails, wherein the two sets of rails are affixed tothe two aluminum plates for mounting rails, wherein the two sets ofrails are connected to roller mounts such that each set of the two setsof rails is connected to one roller mount, wherein the roller mountsprovide for horizontal movement of the z-axis subassembly via the twosets of rails; wherein the z-axis subassembly includes a spine having atop end and a bottom end, wherein the spine includes two structuralextruded aluminum profile components, wherein the bottom end includes anattachment point for an idle sprocket, wherein the top end includes anattachment point for mounting a motor, a gear reducer, and a drivesprocket, wherein the z-axis subassembly further includes a chassissubassembly including a multiplicity of bearing blocks attached to achassis, wherein the chassis subassembly is operable to move verticallyalong the spine, wherein the y-axis subassembly is attached to thez-axis subassembly via the chassis; wherein the y-axis subassemblyincludes the arm, wherein the arm includes two spaced apart structuralextruded aluminum profile arm components, wherein the two spaced apartstructural extruded aluminum profile arm components are spaced apart toallow for insertion of a timing belt, wherein two linear rails aremounted to the top of the two spaced apart structural extruded aluminumprofile arm components so that they are parallel to the two spaced apartstructural extruded aluminum profile arm components, wherein the y-axissubassembly further includes four bearing blocks for mounting thetheta-axis subassembly; wherein the theta-axis subassembly includes theEOAT subassembly for moving the at least one object, a motor, and aprecision rotary bearing subassembly; and wherein neither the y-axissubassembly, the z-axis subassembly, nor the x-axis subassembly aremounted from the top of the compact palletizer or from the multiplicityof horizontal extruded aluminum profile bars.
 20. The compact palletizerof claim 19, wherein the end of the y-axis subassembly which is notattached to the chassis is operable to flex between about 0 millimetersand about 3.175 millimeters from a plane horizontally perpendicular tothe x-axis subassembly.
 21. The compact palletizer of claim 18, whereinthe multiplicity of vertical posts are extruded aluminum profilevertical posts and the multiplicity of horizontal bars are extrudedaluminum profile horizontal bars.
 22. The compact palletizer of claim18, wherein the compact palletizer has a total height of about 3.35meters and a stack height of about 2.57 meters.
 23. The compactpalletizer of claim 18, further comprising a plurality of panelscomprised of polycarbonate and/or aluminum, wherein the plurality ofpanels are affixed to the multiplicity of vertical posts and/or themultiplicity of horizontal bars.
 24. The compact palletizer of claim 18,wherein the frame and the assembly do not include welded components. 25.The compact palletizer of claim 18, wherein the compact palletizer has atotal height of about 2.57 meters and a stack height of about 2.44meters.
 26. A compact palletizer comprising: a skeleton including asteel base and a frame; and an assembly including an arm with an end ofarm tooling (EOAT) subassembly for moving at least one object; whereinthe compact palletizer does not measure more than about 3.35 meters inheight when assembled; and wherein a stack height of the compactpalletizer is at least about 2.44 meters; wherein the assembly furtherincludes an x-axis subassembly, a z-axis subassembly, and a y-axissubassembly; wherein the frame further includes an x-axis structure, amultiplicity of vertical posts, and a multiplicity of horizontal bars;wherein the x-axis structure includes two horizontal support beamsrigidly fixed between two vertical end plates; wherein the x-axissubassembly is affixed to the x-axis structure, and the x-axissubassembly provides an interface for mounting at least two z-axismounts of the z-axis subassembly to the x-axis subassembly, wherein theat least two z-axis mounts provide for horizontal movement of the z-axissubassembly; wherein the z-axis subassembly includes a chassissubassembly and a spine having a top end and a bottom end, wherein thechassis subassembly is operable to move vertically along the spine andwherein the y-axis subassembly is attached to the z-axis subassembly viathe chassis; wherein the y-axis subassembly includes an arm including anend of arm tooling (EOAT) subassembly for moving at least one object;wherein neither the y-axis subassembly, the z-axis subassembly, nor thex-axis subassembly are mounted from the top of the compact palletizer orfrom the multiplicity of horizontal bar; and wherein the end of they-axis subassembly which is not attached to the chassis is operable toflex between about 0 millimeters and about 3.175 millimeters from aplane horizontally perpendicular to the x-axis subassembly.
 27. Thecompact palletizer of claim 26, wherein the frame, the x-axis structure,and the assembly do not include welded components.
 28. A compactpalletizer comprising: a skeleton including a base, a frame, and anx-axis structure; and an assembly including an x-axis subassembly, az-axis subassembly, and a y-axis subassembly, wherein the frame includesa multiplicity of vertical posts and a multiplicity of horizontal bars;wherein the x-axis structure includes two horizontal support beamsrigidly fixed between two vertical end plates; wherein the x-axissubassembly is affixed to the x-axis structure, and the x-axissubassembly provides an interface for mounting at least two z-axismounts of the z-axis subassembly to the x-axis subassembly, wherein theat least two z-axis mounts provide for horizontal movement of the z-axissubassembly; wherein the z-axis subassembly includes a chassissubassembly and a spine having a top end and a bottom end, wherein thechassis subassembly is operable to move vertically along the spine andwherein the y-axis subassembly is attached to the z-axis subassembly viathe chassis; wherein the y-axis subassembly includes an arm including anend of arm tooling (EOAT) subassembly for moving at least one object;wherein neither the y-axis subassembly, the z-axis subassembly, nor thex-axis subassembly are mounted from the top of the compact palletizer orfrom the multiplicity of horizontal bars; wherein the frame, the x-axisstructure, and the assembly do not include welded components; whereinthe multiplicity of vertical posts, the multiplicity of horizontal bars,the two horizontal support beams, and the two vertical end plates areconstructed of extruded aluminum profile, and wherein the spine includesextruded aluminum profile components; and wherein during assembly of thecompact palletizer, the multiplicity of vertical posts are affixed tothe base between about 1 degree and about 2 degrees from a planevertically perpendicular to the base, such that when the multiplicity ofhorizontal bars are affixed to the multiplicity of vertical posts, themultiplicity of vertical posts become oriented vertically perpendicularto the base and the multiplicity of vertical posts and the multiplicityof horizontal bars are pretensioned or prestressed by the verticallyperpendicular orientation of the vertical posts.